Sustainable packaging for bakery products

Do you value environmental protection and are looking for sustainable packaging for your bakery products? With Schubert Packaging Perspectives, you’ve come to the right place.

The demands made on packaging are becoming increasingly stringent. It needs to preserve baked goods, protect them from damage and ensure that they are attractive on the shelf. Additionally, the demand for sustainability is growing – from both consumers and legislators. As part of our Packaging Perspectives service, we develop solutions that bring together functionality, cost-effectiveness and sustainability. Let our experts advise you on how you can design your baked goods packaging sustainably.

Packaging materials for sustainably packaging bakery products

With our extensive expertise, experience and innovative packaging lines, we support manufacturers in packaging their bakery products sustainably, reliably and efficiently. Find out what options are available to you for the various packaging materials here:

Packaging materials

Valentin Köhler develops sustainable packaging

Leveraging potential through packaging optimisation

In addition to selecting more environmentally friendly materials, there are other adjustments you can make to achieve greater sustainability. Here at Schubert, for example, we can help you optimise the cutting, material thickness and machinability of your baked goods packaging. Find out exactly what we can do for you here:

Packaging optimisation

A packaging machine for packaging bakery products sustainably

Clean processes, less waste

The same applies to the packaging of bakery products: The less waste is produced, the better it is for the environment. To achieve this, secure and economical processes are essential – from the production of your baked goods to sustainable packaging and transport to the retailer. We analyse every step in detail and identify potential for improvement. Find out how here:

Process optimisation

Packaging materials for bakery products

More environmentally friendly packaging materials such as paper, cardboard, monofilms or hybrid materials with a lower plastic content are decisive when it comes to sustainability. However, it is important that your sustainable packaging for baked goods is also suitable for automation and can be processed by the packaging machine. Our packaging systems process conventional and environmentally friendly materials with equal security and efficiency, providing you with a choice.

A sustainable solution: Cardboard packaging for bakery products

When you think of sustainable packaging solutions for baked goods, do you think of cardboard? Then you’re right. On the one hand, cardboard is made from wood, a renewable raw material. And on the other, it can be easily returned to the recycling cycle. This is also demonstrated by the high recycling rates throughout the EU. Schubert has decades of experience with cardboard as a packaging material and has gained a great deal of expertise in this area. Our cartoners and casepackers pack your sensitive baked goods carefully, efficiently and compactly. And they cover a wide range of cardboard packaging: from various types of boxes to shipping crates or shelf-ready packaging solutions directly for the sales shelf. We will not only supply you with standard packaging for your baked goods, we will also be delighted to accommodate your special requirements. For example, our robot-assisted technology can also be used to produce high-quality assortment packaging with inlay paper, special box formats or the careful handling of packaging with sensitive, highly refined surfaces.

Sustainable solid cardboard box for baked goods

Boxes made from solid cardboard

Many baked goods are fragile and can easily be crushed or damaged. With secondary packaging made of solid cardboard, you can protect your products and give them a high profile on the shelf at POS. Depending on the type of baked goods, loading method, machine concept and output, there are many possible box designs. For example, you can also select whether the hinged lid should open upwards (top-open) or to the side (side-open) when it comes to removing your delicious treats. Either way, your tasty products will always be easily accessible to the consumer.

Transport boxes made from corrugated cardboard

Shipping boxes are available in FEFCO 0201 design or as a wrap-around. In all cases, they have the potential for sustainable packaging. Both types offer additional advantages for baked goods. FEFCO is often the less expensive solution, but the wrap-around has a compact design in which the products are enclosed in a flat and precisely moulded corrugated cardboard blank.

Shelf-ready packs as packaging for baked goods: Sustainable & ready to use

Shelf-ready packs (SRP) can be stacked multiple times on the shelf and offer consumers an excellent view of the various products. SRPs can be used as one-piece or multi-piece packs, i.e. with a separate lid that can be easily removed so that the cartons can be used directly at POS. They also protect the baked goods securely during transport and are fully recyclable as corrugated cardboard packaging.

Casepacker for sustainable pick-up packaging

Cartoners & casepackers for sustainably packaging baked goods

All carton packaging is flexibly erected, loaded and closed by our modular cartoners and casepackers. For your formats – i.e. the respective combination of baked goods and packaging – we will either develop a customised machine layout for you or recommend our lightline Cartonpacker for fast, cost-effective automation in compact form. Regardless of which variant you choose, our lines are durable, easy to handle and can switch effortlessly between different formats. What they all have in common is a process that makes the packaging of baked goods both sustainable and economical.

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Flow-wrapping machines for more environmentally friendly films

From bread and cakes to croissants – many baked goods are packaged in flowpacks. These practical films are popular because they provide the products with a reliable barrier against moisture, oxygen and other external influences – thereby preserving their freshness and shelf life. Baked goods can also be attractively presented over a longer period of time and, thanks to various printing and finishing options, flowpacks leave nothing to be desired from a marketing perspective. Plastic composite films are generally used as the material for flowpacks because they have a high barrier against air exchange and are highly tear-resistant. However, they are not recyclable and therefore not very sustainable. More environmentally friendly films for baked goods, on the other hand, cause difficulties for many packaging systems because, for example, they do not tolerate heat during sealing. This is why we have designed our Flowpacker – the flow-wrapping machine from Schubert – to be able to switch flexibly between conventional and sustainable materials. Whether composite films, recyclable monofilms or paper-based films – the choice is yours!

A composite film flowpack made of different layers in white

Composite films: Several different films create an integrated whole

Composite films consist of several layers of different base materials that are joined together. In the baked goods industry, these are usually aluminium/plastic combinations that are used for flexible packaging solutions such as flowpacks. By combining different films, properties such as UV, light or barrier protection can be customised through different combination options – depending on the product to be packaged. There is a disadvantage however: Because the technology for recognising and separating the composite films into mono materials is not yet fully developed, materials made from several layers are difficult to recycle and therefore not sustainable.

A reusable, recyclable monofilm in silver

Monofilms: Sustainable for the packaging of baked goods

Monofilms are available in many sizes, qualities and thicknesses. Like composite films, they also consist of several layers, but only of one type of plastic. This is why mono-material packaging is considered reusable and recyclable, as the ‘regranulate’, i.e. the material obtained through recycling, can be fed back into the plastic cycle. Soft and hard polyethylene as well as polypropylene (PP) and polyamide (PA) are usually used for mono materials.

Paper-based films – more robust than you might think

Paper is ideal for the sustainable packaging of baked goods. The fear that it may not adequately protect the products can be refuted, as paper-based packaging materials can also be provided with the necessary barrier or sealing properties. These are achieved by laminated or extruded films, or by coatings. Fibre-based films with water-soluble dispersion coatings are more environmentally friendly, as they are considered more recyclable. However, baked goods manufacturers can use both variants on Schubert systems.

A Schubert Flowpacker packs products into flowpacks

The Flowpacker – Schubert’s flow-wrapping machine

As a flexible module, the Flowpacker can be integrated at various points in the packaging process. For example, baked goods can be individually wrapped into flowpacks or several baked goods in a primary packaging such as a cardboard tray can then be sealed with a flowpack. Regardless of where the Flowpacker is used, it guarantees a flawless, high-quality packaging process thanks to advanced integrated quality controls. The forming shoulders developed in-house by Schubert and the latest hot and cold sealing technologies process conventional materials, recyclable flowpacks made from monofilms or paper-based films equally quickly and with high quality. Even very thick films that require longer sealing times can be processed without causing any problems.

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Trays

Baked goods vary in shape, size and texture, as do the trays in which they are packaged. Here too, protection against damage to the product and shelf life are paramount. Because they are used as primary packaging, it is recommended that they are designed to be as space-saving as possible and easy to insert into subsequent packaging. To make trays for baked goods packaging sustainable, many baked goods manufacturers opt for cardboard packaging. At Schubert, we strongly support the choice of sustainable packaging and have designed our pick & place machines so that they can easily handle both plastic and cardboard trays.Our sustainable packaging experts support manufacturers who have not yet opted for sustainable packaging when it comes to packaging their baked goods in a more environmentally friendly alternative, such as cardboard.

Not all plastics are created equal

For some baked goods, especially those that leave behind residues such as grease, manufacturers have so far preferred to use plastic trays rather than cardboard alternatives. But even in this case, the baked goods packaging can look sustainable. For example, by carefully selecting the plastic. For example, mono plastics can also be recycled, as all the individual material layers are made from the same material. Working with thinner or narrower trays are also a way of reducing the use of plastic and doing something positive for the environment.

Sustainable tray packaging for baked goods

Cardboard trays for the sustainable packaging of baked goods

For many baked goods, plastic trays can easily be replaced by cardboard. It is important that product protection is guaranteed throughout the entire life cycle, as not only packaging but also baked goods that have to be disposed of are a burden on the environment. At the same time, care should be taken to ensure optimum machinability, as this is key to avoiding quality fluctuations, faulty packaging and product damage.

Pick & place – intelligent solutions for baked goods

Picking, positioning and placing muffins, biscuits or other baked goods – our Pickerlines can pack baked goods into trays with the utmost precision and maximum speed. As every product is different, our customised robotic tools ensure an ideal grip when picking and packing. From fragile biscuits and greasy donuts to individually shaped croissants, all products are placed reliably and gently into their packaging – reducing waste to a minimum. And our pick & place machines not only switch between different types of baked goods, but also from cardboard to plastic and back again without any problems.

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Optimising baked goods packaging

Many manufacturers already use cardboard packaging for their baked goods, but would like to be even more environmentally friendly. The good news is that, over and above selecting the most sustainable packaging material for the product in question, there are further options for making bakery packaging more sustainable.

Important factors include the cut, material thickness and machinability. For example, a general revision of the formats, smaller cuts of the bakery packaging or thinner trays ensure that less material is used overall. Our packaging development experts will take a close look at your packaging together with you and identify potential improvements for greater environmental friendliness.

However, for many baked goods manufacturers, environmental friendliness is only one of the important features of packaging. This is why we also look at other factors, such as the appeal of the packaging at POS or availability of the required packaging material on the market, in order to find the right solution for you and your specific formats.

Sustainable materials

What materials make baked goods packaging sustainable? Currently, these are primarily materials that are recyclable, i.e. that can be returned to the material cycle. Because composites combine materials with different properties, they are often difficult to separate and cannot be recycled at all or only with great effort. On the other hand, mono materials made of plastic and, in particular, cardboard can be returned to the material cycle very easily. At Schubert, we know that in many cases plastic can be replaced by cardboard, even for baked goods that require a high level of protection. Whenever possible, we present our customers with ecological alternatives.

Sustainable packaging concepts

As an innovation driver for the packaging industry, Schubert not only prioritises sustainable materials, we also go one step further. Because even though our focus is on modular, digital and robot-based packaging machines, we sometimes go on research trips and develop new sustainable packaging concepts. One of these, for example, is Dotlock, a technology that enables cardboard packaging to be produced entirely without glue. Dotlock is based on so-called ‘clinching technology’ used for joining metals. The cardboard packaging is pierced with a needle from one side, forming a collar on the other side. This is then pressed onto the cardboard to create a stable force & form fit. As a 100 per cent glue-free packaging solution, Dotlock is fully recyclable via the paper cycle. Find out more about our innovative Dotlock technology here.

Smaller blanks – every millimetre counts

Our innovative robots work extremely precisely, quickly and reliably. They achieve this thanks to the image processing system developed by Schubert. It recognises the position and shape of the products and places them in their intended location into boxes, cartons or trays – with millimetre precision. Thanks to our robots’ high-precision performance, you can select smaller blanks for your packaging: Even a few millimetres add up to substantial material savings and make baked goods packaging more sustainable.

A single unit: the packaging and the machine

Faults or errors in packaging processes can be extremely time-consuming and costly. This makes it all the more important to ensure good machinability right from the design stage of bakery packaging. The material thickness and strength of the packaging therefore need to be considered not only from an environmental point of view, but also with regard to a smooth process in the machine. Moreover, the more blanks or trays fit next to each other in a machine magazine, the more output can be achieved in the line. We take all these different requirements into account in our packaging development.

Professional packaging development from Schubert

Highly efficient, flexible and modular packaging machines are our core business – and packaging your baked goods is intrinsically linked to this. Our packaging development experts will help you optimise your packaging and therefore produce more sustainably.

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Efficient processes from A to Z

It’s a long journey from the individual ingredients to the dough and all the way to the packaged baked bread. Well-designed packaging processes are a key factor when it comes to cost-effectiveness. Moreover, the smoother the processes can run, the fewer baked goods have to be rejected during the packaging process. It is also important in the baked goods industry to reduce waste and achieve greater sustainability.

We have set ourselves ambitious goals when it comes to avoiding waste, and we support baked goods manufacturers in reducing their waste to as close to zero as possible. We can ensure this with a reliable packaging process and gentle handling of the fragile baked goods. We will also adapt our modular Schubert lines flexibly to your new parameters in the event of product modifications or launches. Thinking outside the box is also essential. We include upstream and downstream production and packaging steps in our planning. And if you would like to think even further ahead with us, the experienced teams from Schubert-Consulting will also analyse the entire supply chain – from raw materials all the way through to recycling.

A focus on sustainability upstream and downstream of the machine

Anyone who opts for sustainable baked goods packaging should also look at the associated processes. For example, a machine concept with a capacity buffer helps prevent overproduction of baked goods. Optimising or reducing the packaging layout can lead to less space being required during transport and thereby reduce CO2 emissions. In order to capitalise on this untapped potential, we recommend involving our Schubert experts in a new project as early as possible. You’ll benefit from even greater opportunities to establish sustainability along the entire process chain.

A tablet with the evaluation of digital figures

4YOU Digital Services for machine availability you can count on

In this day and age, data is one of the most important currencies. This also applies to digital machine data, which provides information about current actual conditions – and serves as the basis for subsequent process and performance improvements. At Schubert, we collect and analyse digital machine data as part of our 4YOU CARE Services (Connection for Analytics, Reporting and Efficiency). This enables us to help you keep your packaging systems efficient in the long term and, if necessary, retool them to take on new tasks. After all, high machine availability is a key factor in the sustainable production of baked goods. Products coming out of the oven can’t wait, they have to be processed immediately to maintain their quality. Unplanned downtime is a real problem, as all too often valuable baked goods need to be disposed of as a result. You can rely on our 4YOU Services to ensure that machine downtime never becomes an issue for you.

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Sustainable baked goods packaging with Schubert-Consulting

Are you looking to scrutinise your packaging process more closely? Are you keen to focus on greater environmental awareness? And would you like more of a holistic approach?
On request, our experienced consultants at Schubert-Consulting can look at the issue of sustainability across the entire baked goods supply chain – from the use of raw materials all the way to the consumer. Whatever your requirements, we will determine the best materials for you, design packaging, analyse your logistics and digitalise your processes.

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Practical examples of sustainability in the bakery products sector

Flexibility and high precision are at the heart of our innovative packaging machines. These basic requirements are the foundation on which environmentally friendly packaging for bakery products can be achieved. Take a look at how some of our customers have integrated more sustainability into their packaging processes.

Boxes instead of labels

By using folding boxes instead of adhesive labels and thinner films, Bahlsen saves 112 tonnes of plastic per year when packaging its “PiCK UP!” biscuits.

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A casepacker for Balocco with sustainable packaging

An option for paper-based films

Biscuit manufacturer Balocco is well positioned thanks to flexible sealing technology for conventional and paper-based films.

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Automated, cost-effective baked goods packaging

Increased energy costs, inflation and labour shortages – the bakery products sector is currently facing major challenges. If you would like to automate not only your production processes but also your packaging processes, we can provide you with the right solution with our robot-supported modular TLM systems. Whether you are producing fragile biscuits, crispy croissants or bread roll dough pieces for the frozen food counter, we can help you pack your products economically and cost-effectively. Find out more about our packaging machines for bakery products today.